CN111902235A

CN111902235A - Induction heating extension cable comprising control wires

Info

Publication number: CN111902235A
Application number: CN201980019455.9A
Authority: CN
Inventors: 安东尼·V·萨利士; 保罗·韦尔哈根
Original assignee: Illinois Tool Works Inc
Current assignee: Illinois Tool Works Inc
Priority date: 2018-03-22
Filing date: 2019-03-22
Publication date: 2020-11-06
Also published as: CA3093005A1; WO2019183478A1; EP4329426A2; CA3093005C; EP4329426A3; EP3768458A1; EP3768458B1

Abstract

An induction heating extension cable including a control wire is disclosed. An example cable assembly includes: a first plurality of wires arranged in a litz cable; an outer protective layer configured to protect the plurality of wires from physical damage; and a second plurality of wires electrically isolated from the first plurality of wires and protected from physical damage by the outer protective layer.

Description

Induction heating extension cable comprising control wires

This international application claims priority from U.S. patent application serial No. 15/928,272 entitled "INDUCTION HEATING extension cable INCLUDING CONTROL wires" filed on 3, 22/2018. U.S. patent application No. 15/928,272 is incorporated herein by reference in its entirety.

Background

Induction heating of a workpiece (e.g., a pipe) to be welded typically involves placing a fixture and/or one or more conductive cables in proximity to the workpiece. The power supply providing the induction heating power may be positioned at a substantial distance from the workpiece and/or the fixture, so that measuring the heating parameters directly at the power supply is not feasible.

Disclosure of Invention

An induction heating extension cable including a control wire is disclosed, substantially as shown in and described in connection with at least one of the figures, as set forth more completely in the claims.

Drawings

Fig. 1A is a block diagram of an example induction heating system including a cable assembly constructed in accordance with aspects of the present disclosure.

Fig. 1B is a block diagram of another example induction heating system, according to aspects of the present disclosure.

Fig. 2 is an example embodiment of the cable assembly of fig. 1A and/or 1B.

The figures are not necessarily to scale. Where appropriate, like or identical reference numerals are used to indicate like or identical parts.

Detailed Description

Induction heating extension cables (induction heating extension cables) carry induction heating current between an induction heating power supply (e.g., a power supply that generates and/or converts induction heating current) and an induction heating cable (e.g., a cable positioned proximate to a workpiece such that the induction heating current induces eddy currents within the workpiece). The induction heating extension cable may tightly couple these conductors carrying induction heating current to reduce (e.g., minimize or eliminate) leakage and improve efficiency.

Unlike conventional cables, the disclosed example extension cables contain additional control cables that carry data and/or power and are contained within an outer protective layer of the extension cable (e.g., not outside of the extension cable). The disclosed example extension cable couples the induction heating power supply to a remote device positionable proximate the workpiece to exchange data with and/or provide power to the remote device. Furthermore, the disclosed examples may omit electrical isolation measures that may be required when electrically coupling data to high power heating wires, while being protected from physical damage that may occur in a welding-type environment by a relatively stiff outer jacket or protective layer of the extension cable.

An example cable assembly is disclosed that includes: a first plurality of wires arranged in a litz cable; an outer protective layer configured to protect the first plurality of wires from physical damage; and a second plurality of wires electrically isolated from the first plurality of wires and protected from physical damage by the outer protective layer.

In some example cable assemblies, the second plurality of wires comprises twisted pairs. In some example cable assemblies, the second plurality of wires comprises coaxial wires. Some example cable assemblies also include a coupler to couple the first plurality of wires to an induction heating cable and to couple the second plurality of wires to an induction heating accessory. In some such examples, the second plurality of wires conduct at least one of power or data between the induction heating accessory and the induction heating power supply.

In some examples, the first plurality of wires is configured to conduct an induction heating current. In some examples, the first plurality of wires have a total cross-sectional area of at least 8.37 square millimeters without including an electrically insulating material. Some example cable assemblies also include a coupler to couple the first plurality of wires to an induction heating power supply and to couple the second plurality of wires to an induction heating power supply. In some such examples, a coupler couples the first plurality of wires to a power connector of an induction heating power supply. In some examples, a coupler couples the second plurality of wires to a communication connector of an induction heating power supply.

A disclosed example induction heating system includes an induction heating power supply, a monitoring device remote from the induction heating power supply, and a cable assembly. The cable assembly includes: a first plurality of wires arranged in a litz cable; an outer protective layer configured to protect the first plurality of wires from physical damage; and a second plurality of wires electrically isolated from the first plurality of wires and protected from physical damage by the outer protective layer.

In some examples, the second plurality of wires comprises twisted pairs. In some examples, the second plurality of wires comprises coaxial wires. Some example induction heating systems also include a coupler for coupling the first plurality of wires to an induction heating cable and the second plurality of wires to a monitoring device. In some such examples, the second plurality of wires conduct at least one of power or data between the monitoring device and the induction heating power supply.

In some example induction heating systems, the first plurality of wires conducts an induction heating current. In some examples, the first plurality of wires have a total cross-sectional area of at least 8.37 square millimeters without including an electrically insulating material. Some example induction heating systems also include a coupler to couple the first plurality of wires to an induction heating power supply and to couple the second plurality of wires to an induction heating power supply. In some such examples, a coupler couples the first plurality of wires to a power connector of an induction heating power supply. In some examples, a coupler couples the second plurality of wires to a communication connector of an induction heating power supply.

Fig. 1A is a block diagram of an example induction heating system 100 including a cable assembly 102. The heating system 100 includes an induction heating power supply 104, which induction heating power supply 104 provides heating power to the workpiece 106 via the cable assembly 102 and the induction heating cable 107. The system 100 also includes an induction heating monitor 108. The induction heating monitor 108 may be a monitoring device for monitoring the workpiece 106 and/or may be any other type of induction heating accessory.

The cable assembly 102 includes an outer protective layer 110, a plurality of

wires

112a, 112b in a Litz configuration (Litz configuration), and a second set of two or more wires 114. The

litz wires

112a, 112b provide current to the heater cable 107. When the heater cable 107 is disposed proximate the workpiece 106 (e.g., wound around the workpiece 106, attached to a fixture configured to direct electrical current to the workpiece 106), the power supply 104 and the heater cable 107 induce eddy currents in the workpiece 106 to inductively heat the workpiece 106. In some examples, the effective gauge of each of the

example litz wires

112a, 112b can be equivalent to an American Wire Gauge (AWG)8 (e.g., a total cross-sectional area of at least 8.37 square millimeters without including the electrically insulating material of the litz wire) or greater. In examples where each of the

litz wires

112a, 112b is implemented using a plurality of litz wires, the effective gauge of the combination of litz wires used to implement each of these litz wires is equivalent to an AWG 8 or greater (e.g., the combined total cross-sectional area of the plurality of wires implementing the litz wire 112a is at least 8.37 square millimeters and the combined total cross-sectional area of the plurality of wires implementing the litz wire 112b is at least 8.37 square millimeters without the inclusion of electrically insulating material for the litz wires). In other examples, the effective gauge of the combination of the

litz wires

112a, 112b may be equivalent to the AWG 8 (e.g., the gauge of each of the

litz wires

112a, 112b may be equivalent to less than the AWG 8).

The second wire 114 is contained within the outer protective layer 110 (e.g., outer jacket) of the cable assembly 102, but is electrically isolated from the

litz wires

112a, 112b so as to be isolated from relatively high currents and/or voltages. An exemplary outer protective layer 110 can use for example a thermoplastic polyester elastomer (e.g.,

) Polyurethane, and/or any other material and/or combination of materials that provides mechanical and electrical protection to the

litz wires

112a, 112b and the second wire 114. The second wire 114 may deliver power to the induction heating monitor 108 and/or exchange data signals between the power supply 104 and the induction heating monitor 108. Example embodiments of the second conductor 114 include one or more twisted pairs of conductors, or one or more coaxial cables. Other embodiments may also be used.

The example cable assembly 102 of fig. 1A also includes a power supply coupler 116 and a heating cable coupler 118. The power supply coupler 116 couples the

wires

112a, 112b to power terminals 120a, 120b (e.g., positive and negative terminals) of the induction heating power supply 104 and/or couples the second wire 114 to a communication terminal 122 of the induction heating power supply 104. The power terminals 120a, 120b may be studs that transmit heating power for heating the workpiece 106 via the induction heating cable 107. The example induction heating power supply 104 can exchange data with the induction heating monitor 108 and/or provide power to the induction heating monitor 108 via the communication terminal 122. In some examples, the power terminals 120a, 120b and the communication terminal 122 are integrated into the same connector to which the power supply coupler 116 may be connected.

A heater cable coupler 118 couples the

wires

112a, 112b to the induction heater cable 107. The heater cable coupler 118 also couples the wires 114 to the induction heating monitor 108 via external wires 124. The external conductor 124 may be of the same type as the conductor 114 within the cable assembly 102. For example, if the conductor 114 comprises a plurality of twisted pairs, the outer conductor 124 may also comprise a plurality of twisted pairs. The external leads 124 may be replaceable such that an appropriate length of external leads 124 may be used to position the induction heating monitor 108 at a desired location.

The example induction heating monitor 108 is in communication with the induction heating power supply 104 via the wires 114 of the cable assembly 102. As described above, the wire 114 is electrically isolated from the

wires

112a, 112b carrying the induction heating power, and the wire 114 and

wires

112a, 112b are contained within the outer protective layer 110 of the cable assembly 102. In the example of fig. 1A, the induction heating monitor 108 communicates and/or receives power via wires 114 within the extension cable. However, the wire 114 may also be at least partially contained within the heater cable 107.

The induction heating monitor 108 includes a communication circuit 126, a control circuit 128, a data collection circuit 130, a power circuit 132, an energy storage device 134, a user interface 136, and a sensor interface 138. The example communication circuit 126 includes a transmitter circuit 140 and a receiver circuit 142.

The example transmitter circuit 140 communicates induction heating data via the wire 114 to the induction heating power supply 104 via the external wire 124 and the heater cable coupler 118. The example receiver circuit 142 may receive data from the induction heating power supply 104. The induction heating power supply 104 may include similar communication circuitry, including transmitter circuitry and/or receiver circuitry, to receive induction heating data and/or transmit configuration data to the induction heating monitor 108. In some examples, the induction heating power supply 104 modifies the induction heating output (e.g., induction heating power, etc.) based on induction heating data received from the induction heating monitor 108 via the lead 114.

The transmitter circuitry 140 frames the induction heating data for transmission over the conductor 114. The induction heating data may be generated from sensor data collected by one or more sensors 144 via sensor interface 138 and/or data collection circuitry 130. The data collection circuit 130 may include a sensor digitizer 146 for digitizing data received from the sensor 144. The induction heating data may be converted to digital data via the sensor digitizer 146 and/or input by a user or operator via the user interface 136.

Example sensors 144 may include temperature sensors (e.g., thermocouples, thermistors, resistive temperature devices, infrared sensors, semiconductor-based temperature sensors, etc.), coolant pressure sensors, or coolant flow sensors, and/or position sensors. Example induction heating data includes one or more of: the ambient temperature at which the workpiece 106 is heated with the induction heating cable 107, the temperature of a blanket (blanket) in contact with the induction heating cable 107, the temperature of the workpiece 106, a measurement of the current flowing through the induction heating cable 107, a voltage measurement of the voltage at the induction heating cable 107 (e.g., the voltage across the portion of the induction heating cable 107 that is inductively coupled to the workpiece 106), an error signal, the temperature of the coolant flowing through the induction heating cable 107, the coolant pressure, the coolant flow rate, a workpiece identifier, an induction heating cable identifier, an operator identifier, date information, time information, geographic information, a cable clamp identifier, and/or any type of operator or user input entered at the induction heating monitor 108.

Power circuit 132 draws power from conductors 114, 124, which may be multiplexed with the data signal. The power circuit 132 provides power to the data collection circuit 130, the sensor 144 (e.g., via the sensor interface 138), the control circuit 128, the user interface 136, and/or the communication circuit 126. Additionally or alternatively, the power circuit may charge the energy storage device 134. The example energy storage device 134 provides power to the data collection circuit 130, the sensors 144 (e.g., via the sensor interface 138), the control circuit 128, the user interface 136, and/or the communication circuit 126 when the power circuit 132 is unable to power the components. Example energy storage devices 134 may include one or more batteries, one or more capacitors, and/or any other type of energy storage device.

The example user interface 136 may include any type of user interface device, such as selection buttons, switches, dials, numeric keypads, touch screens, and/or any other type of user interface device.

Fig. 1B is a block diagram of another example induction heating system 150. The induction heating system 150 of fig. 1B is similar to the induction heating system 100 of fig. 1A and includes a cable assembly 102, an induction heating power supply 104, a workpiece 106, an induction heating cable 107, an induction heating monitor 108, an outer protective layer 110, wires 112a, 112B in a litz configuration, a second set of two or more wires 114, a power supply coupler 116, power terminals 120a, 120B, and a communication terminal 122.

Unlike the example system 100 of fig. 1A, the example system 150 couples the cable assembly 102 to the induction heating monitor 108 instead of the heating cable coupler 118. The example induction heating monitor 108 receives power and/or data via the second wire 114 (e.g., by terminating the second wire 114). The induction heating monitor 108 of fig. 1B transfers heating power from the wires 112a, 112B all the way to the heater cable 107. In some examples, the induction heating monitor 108 may include connectors and/or terminals for the

wires

112a, 112b and for the heater cable 107, and include through wires for connecting the

wires

112a, 112b and the heater cable 107.

The example induction heating monitor 108 of fig. 1B includes communication circuitry 126, control circuitry 128, data collection circuitry 130, power circuitry 132, energy storage device 134, user interface 136, and sensor interface 138. The induction heating monitor 108 collects induction heating data from one or more sensors 144.

Although example couplers 116, 118 are disclosed, the example cable assembly 102 may be coupled to the induction heating power supply 104, the heating cable 107, and/or the induction heating monitor 108 using any combination and/or type of couplers and/or hardwires.

Fig. 2 is an example embodiment of the cable assembly 102 of fig. 1A and/or 1B. The example cable assembly 102 includes four litz wire bundles 202, two wires 204 arranged in a twisted pair configuration, an outer jacket 206, and an inner wrapping material 208. Each of the litz wire bundle 202 and the wires 204 includes an additional jacket 210, which additional jacket 210 may be constructed of a thermoplastic elastomer (TPE). The example outer jacket 206 is formed from a thermoplastic polyester elastomer (e.g.,

) Polyurethane, and/or any other material and/or materials that provide mechanical and electrical protection to the litz wire bundle 202 and the wires 204And (4) combining and forming. The inner wrap 208 may be constructed using Polytetrafluoroethylene (PTFE) tape.

As shown in fig. 2, the outer jacket 206 provides an outer protective layer that protects the litz wire bundle 202 and the twisted pair of conductors 204 from physical damage.

As used herein, "and/or" refers to any one or more items in a list that are connected by "and/or". By way of example, "x and/or y" refers to any element of the three-element set { (x), (y), (x, y) }. In other words, "x and/or y" means "one or both of x and y". As another example, "x, y, and/or z" refers to any element of the seven-element set { (x), (y), (z), (x, y), (x, z), (y, z), (x, y, z) }. In other words, "x, y, and/or z" refers to "one or more of x, y, and z. The term "exemplary", as used herein, is intended to serve as a non-limiting example, instance, or illustration. As used herein, the terms "as (e.g.)" and "for example" (for example) "set forth a list of one or more non-limiting examples, instances, or illustrations.

While the present method and/or system has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the method and/or system. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. For example, blocks and/or components of the disclosed examples may be combined, divided, rearranged, and/or otherwise modified. Therefore, it is intended that the present method and/or system not be limited to the particular embodiments disclosed, but that the present method and/or system will include all embodiments falling within the scope of the appended claims, both literally and under the doctrine of equivalents.

Claims

1. An induction heating monitoring apparatus configured to communicate with an induction heating power supply via one or more first wires of an induction heating cable, the one or more first wires being electrically isolated from one or more second wires configured to carry induction heating power, the one or more first wires and the one or more second wires being contained within an outer sheath of the induction heating cable.

2. The apparatus of claim 1, wherein the induction heating cable comprises an extension cable configured to conduct current between the induction heating power supply and an induction heating coil.

3. The apparatus of claim 1, comprising:

a data collection circuit configured to collect induction heating data associated with an induction heating operation performed using the induction heating power supply; and

a communication circuit configured to communicate via the one or more first conductors.

4. The device of claim 3, wherein the communication circuitry comprises at least one of:

a transmitter circuit configured to communicate the induction heating data to the induction heating power supply; or

A receiver circuit configured to receive configuration data from the induction heating power supply.

5. The device of claim 3, further comprising a power circuit configured to receive power via the one or more first conductors and provide power to the data collection circuit.

6. The apparatus of claim 3, further comprising a sensor interface configured to receive data from a sensor.

7. The device of claim 6, wherein the data collection circuit further comprises a sensor digitizer configured to digitize data received from the sensor.

8. The device of claim 6, wherein the sensor interface is configured to receive data from at least one of: a thermocouple, thermistor, resistance temperature detector, infrared sensor, semiconductor-based temperature sensor, pressure sensor, flow sensor, or position sensor.

9. The apparatus of claim 1, comprising a first terminal and a second terminal, the first terminal configured to be coupled to the one or more second wires, and the second terminal coupled to the first terminal to be coupled to at least one of an induction heating extension cable or an induction heating pad.

10. The apparatus of claim 1, wherein the one or more second wires comprise litz wire.

11. An induction heating system comprising:

an induction heating power supply; and

a cable assembly, the cable assembly comprising:

a first plurality of wires arranged in a litz cable;

an outer protective layer configured to protect the first plurality of wires from physical damage; and

a second plurality of wires electrically isolated from the first plurality of wires and protected from physical damage by the outer protective layer; and

a monitoring device coupled to the induction heating power supply via the second plurality of wires.

12. The induction heating system of claim 11, wherein the monitoring device is configured to terminate the first plurality of wires and couple the first plurality of wires to an induction heating cable.

13. The induction heating system of claim 11, wherein the monitoring device comprises:

a communication circuit configured to communicate via the second plurality of wires.

14. The induction heating system of claim 13, further comprising a power circuit configured to receive power via the second plurality of wires and provide power to the data collection circuit.

15. The induction heating system of claim 13, further comprising a sensor, the data collection circuit comprising a sensor interface configured to receive data from a sensor.

16. The induction heating system of claim 15, wherein the sensor interface is configured to receive data from at least one of: a thermocouple, thermistor, resistance temperature detector, semiconductor-based temperature sensor, pressure sensor, flow sensor, or position sensor.

17. The induction heating system of claim 13, wherein the induction heating power supply is configured to modify an induction heating output based on the induction heating data.

18. The induction heating system of claim 11, further comprising a coupler configured to couple the first plurality of wires to an induction heating cable and the second plurality of wires to the monitoring device.

19. The induction heating system of claim 11, wherein the first plurality of wires are configured to conduct an induction heating current.

20. The induction heating system of claim 11, wherein the second plurality of conductors comprises at least one of twisted pairs or coaxial cables.